Dometic SPOTZERO SZIII 2000 Installation and operating instructions

USER MANUAL / INSTALLATION GUIDE
SZIII 2000/3000
www.spotzerowater.com

Table of Contents
Introduction ............................................................................................4
Congratulations ......................................................................................5
Acronyms and Definitions .........................................................................5
Safety .........................................................................................................5
Principles of Reverse Osmosis ..............................................................6
Unit Specifications .....................................................................................7
Installation and Commissioning ................................................................8
SZIII Install Kit ............................................................................................9
System Requirements and Operation Guidelines .................................. 10
Plumbing .......................................................................................... 10
Tube Cutting and Installation Procedure for Quick Connect Fittings 10
Electrical ........................................................................................... 11
SZIII Wiring Diagram ............................................................................ 12
SZIII One Line Flow Diagram .............................................................. 13
PRE-FILTRATION ............................................................................... 14
Pre-Filtration Plumbing .................................................................... 14
Overboard Connection ..................................................................... 15
Product to Tank Connection ............................................................. 15
Feed From Watermaker ................................................................... 16
Membrane Supply ............................................................................ 16
Membrane Return ............................................................................ 17
Membrane Product .......................................................................... 17
Operation and Maintenance .................................................................. 18
Operation Specifications ........................................................................ 19
Feed Water Specifications ........................................................... 19
System Standard Operating Parameters ................................................ 20
TEMPERATURE CORRECTION FACTORS FOR MEMBRANE
PRODUCTION ................................................................................... 21
Rejection, Recovery, and Flow Rates ............................................... 22
Components of the SZIII Unit ................................................................. 23
System Controller ............................................................................. 23
Freshwater RO Pump ....................................................................... 23
Membranes ...................................................................................... 23
Membrane Operation Guidelines .................................................... 23
2

Membrane General Guidelines ........................................................ 23
Membrane Replacement and Removal.................................................. 24
Inserting the New Membrane .......................................................... 25
Preparing Unit for Storage or Shipment ................................................ 27
Preparing System for Storage: ......................................................... 27
Recommissioning the System After Storage .................................... 28
Winterization For Your Unit ................................................................... 29
Recommissioning the System After Winterization ........................... 30
Remote LCD Keypad Setup ..................................................................... 30
SZIII Consumable Items .......................................................................... 31
............................................................... 32
Initial Startup .......................................................................................... 32
LCD Touchpad Navigation ...................................................................... 34
SZIII LCD Menu Tree ............................................................................... 35
STANDARD OPERATION.......................................................................... 3
Performing a Freshwater Flush ..............................................................
Bacteriostatic Remineralizer ..................................................................
Troubleshooting .................................................................................... 4
Troubleshooting Guide ........................................................................... 4
Abnormal Product Flow ...................................................................
IS MY SYSTEM WORKING PROPERLY? .................................................... 4
TDS REJECTION .................................................................................
Membrane Cleaning Procedure .......................................................
.................
..............
SZIII System Specification and Parts ........................................................ 4
Bacteriostatic Remineralizer Assembly Drawing.................................... 4
SZIII Motor/Pump Assembly Drawing .................................................... 4
SZIII Pre-Filter ............................... 4
Freshwater Double-Stack Commercial Pre-Filter Assembly Drawing ....
Warranty ...............................................................................................
3
....

=
Introduction
4

Congratulations
Your S SZIII-Series ultra-purification system is a durable piece of equipment that, with proper
care, will last for many years. This user manual outlines installation, operation, maintenance, and
troubleshooting details vital to the sustained performance of your system.
If your system is altered at the site of operation or if the feed water conditions change, please contact
your local dealer or distributor to determine the proper recovery for your application.
NOTE: PRIOR TO OPERATING OR SERVICING THE REVERSE OSMOSIS SYSTEM, THE USER MANUAL MUST
BE READ AND FULLY UNDERSTOOD. KEEP THIS AND OTHER ASSOCIATED INFORMATION FOR FUTURE
REFERENCE AND FOR NEW OPERATORS OR QUALIFIED PERSONNEL NEAR THE SYSTEM.
Acronyms and Definitions
Safety
The safety section of this User Manual outlines the various safety headings used
throughout this manual's text and are enhanced and defined below .
DO NOT UNDER ANY CIRCUMSTANCES REMOVE ANY CAUTION, WARNING, OR OTHER
DESCRIPTIVE LABELS FROM THE SYSTEM.
NOTE INDICATES STATEMENTS THAT PROVIDE FURTHER INFORMATION AND CLARIFICATION
CAUTION
CAUTION: INDICATES STATEMENTS THAT ARE USED TO IDENTIFY CONDITIONS OR
PRACTICES THAT COULD RESULT IN EQUIPMENT OR OTHER DAMAGE.
WARNING
WARNING: INDICATES STATEMENTS THAT ARE USED TO IDENTIFY CONDITIONS
OR PRACTICES THAT COULD RESULT IN INJURY OR LOSS OF LIFE. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN SERIOUS INJURY OR EVEN DEATH.
5

Principles of Reverse Osmosis
How Fresh Water is Produced
Reverse Osmosis or is a process used to remove large volume of contaminants from
water by forcing the fluid through a semi-permeable membrane.
Osmosis
Osmosis is a naturally occurring process where a weak solution will cross a semipermeable
membrane to mix with a highly concentrated solution. For example, a freshwater solution will
naturally want to mix with a saltwater solution.
Reverse Osmosis
To reverse this process work is put into the system using a pump. The pump causes pressure
to build up on the saltwater side of the membrane. This pressure forces water across the
semi- permeable membrane. The membrane is designed to allow the water molecules to
pass while preventing the salt and other solids from doing so. Fresh water is collected on the
other side of the membrane as a result.
6

Unit Specifications
SZIII MODEL 2000 3000
Configuration 1 Vessel 2 Vessels
Feed Water Source Fresh Water Fresh Water
Rate Production GPD (GPM) 2000 (1.39) 3000 (2.08)
Rejection and Flow Rates
FW Nominal TDS Rejection
%
(Spot Zero)
9 % 9 %
Minimum Feed Flow GPM (LPM) 4.2 (15.9) 4.2 (15.9)
Minimum Concentrat
e
Flow
GPM
(LPM)
1 (3.7) 1 (3.7)
Connections
Feed Inch Hose Hose
Product Inch QC 9.5mm QC 9.5mm
Concentrate Inch QC 2.7 mm QC 2.7 mm
Membranes
Membranes Per Vessel 1 1
Membrane Quantity 1 2
Membrane Size 4041 4041
Pumps
FW Pressure Pump Type Vane Vane
FW RO Motor Amps 5.1 5.1
Electrical
Voltage
115V or
230V 50/60Hz
115V or
230V
50/60Hz
Amp Draw 6 6
System Dimensions
Width x Depth x Height inch
(cm)
17.5 x 12.9 x 16.4
(44.5 x 32.8 x 41.6)
17.5 x 12.9 x 16.4
(44.5 x 32.8 x 41.6)
Weight lb. (kg) 70 (31.8) 70 (31.8)
7

Installation and Commissioning
8

SZIII Install Kit
PART NUMBER DESCRIPTION QTY
KIT0005 SZIII Install Kit
1
J0003 Tubing, Nylon, 3/8" OD 50 ft.
J0004
Tubing,
Nylon, 0.50
in. OD
50
ft.
B0021
Elbow
3/8"
QC
4
B0020 Elbow 1/2" QC 4
B0019 Adapter 1/2" QC to 1/2" MNPT 2
B0030 Adapter 3/8" QC to 1/2" MNPT 2
D0047 TDS-EZ HANDHELD TESTER 1
B0059 Adapter 1/2" CTS Stem to 3/8" CTS 2
B0024 Reducer 1/2" QC Stem to 3/8" QC 2
B0058 Adapter 5/8" QC Stem to 3/8" QC 2
H5089 Install Kit 5/16" Hardware Set 1
B0013 Elbow 3/8" QC Stem to 3/8" QC 4
B0010 Elbow 1/2" QC Stem to 1/2" QC 4
E1018 Wrench for Big Clear 4.5" #10 & #20 1
B5001 Locking Clip, 3/8", Install Kit 20pc 1
B5002 Locking Clip, 1/2", Install Kit 20pc 1
H5065 Lubricant Silicone 6 grams 1
B0043 Ball Valve 3/8" QC 1
MN1003 SZIII Manual 1
AE0004 Bacteriostatic Remineralizer Assembly 1
B0048 RELEASE TOOL SET 1
B0052 Adapter 1/2" QC Stem to 15mm QC 1
B0053 Adapter 3/58" QC Stem to 15mm QC Stem 1
B0054 Elbow 15mm QC 1
B0055 Elbow 15mm QC Stem to 15mm QC 1
9

System Requirements and Operation Guidelines
Plumbing
The membranes and Freshwater RO flow of water with
a maximum temperature not to exceed 113°F. Please see Complete Install Guide and the One-Line Flow
Drawing on page 13 for proper plumbing of the system.
Tube Cutting and Installation Procedure for Quick Connect Fittings
Cut the tube square and remove burrs and sharp edges.
Ensure the outside diameter is free of score marks. For
soft or thin-walled tube, we recommend the use of a
tube insert.
Push the tube into the fitting, to the tube stop.
To disconnect, ensure the system is
depressurized, push the collet
square against the fitting. With the
collet held in this position the tube
can be removed.
CAUTION
ANY RESTRICTIONS OR BLOCKAGE IN THE CONCENTRATE LINE CAN CAUSE BACKPRESSURE, WHICH
WILL INCREASE THE OPERATING PRESSURE. THIS CAN RESULT IN DAMAGE TO THE
COMPONENTS.
10

Electrical
The SZIII Series is available in single phase ( ) AC Current only. 115 or 230-volt models are
available with a 50 or 60 Hertz option for the 230-volt unit.
Connect main power supply to main power terminal blocks. Ground main power supply and the
freshwater RO pump to the grounding bus bar. Reference SZIII wiring diagram on page 12. Ensure that
the electrical circuit supplying the system is compatible with the requirements of the unit and capable
of supplying the specified power for the SZIII unit you are installing.
For clarification, SZIII models that have a part number of 9610003810 or 9610003807 are the
115-volt configuration, and units with a part number of 9610003808 or 9610003807 are 230-volt units.
PC BOARD DIP SWITCH SETTINGS
NOTE
IT IS RECOMMENDED THAT A QUALIFIED ELECTRICIAN WIRES YOUR SYSTEM IN
ACCORDANCE WITH ALL APPLICABLE CODES, RULES, AND REGULATIONS.
WARNING
TO REDUCE THE RISK OF ELECTRICAL SHOCK, THE INCOMING POWER SUPLY
MUST INCLUDE A PROTECTIVE GROUND.
SZIII DIP SWITCH SETTINGS
11

Inlet Source
(FWF/IS)
EGND
EGND
L2BP L1 L2HP L2
TDS TL PO/PP CP PF PI/RF CF
BLU
WHT
RED
BLK
WHT
BLK
RED
BLK
WHT
RED
GRN
WHT
GRN
BLK
RED
BLK
RED
BLK
RED
BLK
RED
BLK
RED
B(-)
A(+)
GND
GND
+24VDC
B(-)
A(+)
GND
GND
+24VDC
12

13

Feed from Dock
PRE-FILTRATION
The SZIII is supplied with a 10 sediment pre-filter (Part #:
252404005) that filters out most contaminants over 1 micron, and a GAC/KDF prefilter that
removes chlorine, chloramine, VOCs and heavy metals (Part #: 252404004). An additional commercial-
grade filter configuration is optional with a single 20 commercial prefilter (Part #: 252404301).
The standard short filters act in the same manner as the
allow for more mounting options.
Prefilters should be changed every 100 hours and/or whenever there is a pressure difference of
15 psi or more between the pressure readings before and after the filter. It is imperative that the
prefilters are always installed when operating the unit as the pump used in this system is susceptible to
damage from sediment debris. In addition, if the prefilter becomes clogged and the water flow to the
pump is reduced or interrupted, cavitation will occur and damage the pump.
A Spot Zero system must be operated on filtered water only. Make sure to read all labels and
instructions on the filters before installation and use.
Pre-Filtration Plumbing
Plumb the feed water from the dock into the pre-filter inlet fitting using a customer supplied 1
NPT connection. From the prefilter outlet fitting run white nylon 1/2" Spot Zero tubing to the feed from
pre-filtration fitting.
CAUTION
A traditional carbon block filter must not be used as it will not remove chloramines and will cause
permanent membrane damage.
WARNING
SPOT ZERO SYSTEMS REQUIRE THAT THE SEDIMENT AND KDF/GAC
PREFILTERS ARE INSTALLED WHILE OPERATING. RUNNING THE UNIT
WITHOUT THE FILTERS WILL CAUSE DAMAGE TO THE PUMP AND WILL FOUL
THE MEMBRANES.
CAUTION
Filter Cartridges must be flushed before installing into the system. See page 32 under the initial
startup section to see how to properly flush the prefilters.
14

Overboard Connection
ship overboard line. For most single
unit applications, QC tube may be acceptable, and should be plumbed into the dedicated overboard
connection on the unit.
QC tube to a dedicated overboard connection on the ship.
Product to Tank Connection
It is important for the unit to be plumbed properly to the ships tank. Ensure that there are no
kinks in the line and reduce the number of bends and elbows used in the hose run.
WARNING
SPOT ZERO SYSTEMS REQUIRE THAT THE OVERBOARD MUST NEVER BE
CLOSED OR OBSTRUCTED WHILE SYSTEM IS OPERATIONAL. CLOSING OR
OBSTRUCTING THE OVERBOARD FLOW ON THE SYSTEM MAY CAUSE
PERMANENT DAMAGE TO THE SYSTEM.
WARNING
SHIPS FRESHWATER TANK MUST BE VENTED PROPERLY TO AVOID BACK
PRESSURE ON THE SYSTEM. FAILURE TO DO SO MAY CAUSE PERMANENT
DAMAGE TO THE SYSTEM AND/OR RESULT IN UNDERPERFORMANCE.
WARNING
PRODUCT TO TANK MUST NEVER BE CLOSED OR OBSTRUCTED WHILE SYSTEM
IS OPERATIONAL. CLOSING OR OBSTRUCTING THE PRODUCT FLOW ON THE
SYSTEM MAY CAUSE PERMANENT DAMAGE TO THE SYSTEM AND/OR RESULT
IN UNDERPERFORMANCE.
To Overboard
15

Ship s Freshwater
Tank
Membrane
Assembly
Bacteriostatic
Remineralizer
supplied white
QC tubing from the system to the ship s freshwater tank. If the bacteriostatic remineralizer is not
section on the bacteriostatic remineralizer on pg. 41 to see its purpose.
Feed From Watermaker
FEED FROM
Always install a three-way valve in line with this, so the water can be
diverted to the ships fresh-water tank if required.
Membrane Supply
QC tubing from the
assemblies.
From Watermaker
16

Membrane Return
Membrane Product
assemblies.
Membrane
Assembly
17

Operation and Maintenance
18

Operation Specifications
It is imperative that the operation specifications laid out in this document are followed precisely.
The reverse osmosis process results in the concentration of filtered impurities and neglecting to follow
the operating procedures may cause the impurities to solidify and scale or foul the membranes. To
prevent this, your SZIII system should never be operated over the rated production or above the max
pump pressure of 150psi. Note that the unit will shut off if the pressure exceeds 175psi. Water
temperature and inlet water ppm are variables that affect product flow and pump pressure.
Feed Water Specifications
Nothing has a greater effect on a reverse osmosis system than the feed water quality. The table
below shows the maximum and minimum levels allowed for the membranes used in this system.
CAUTION
The rated production will have to be corrected for temperature of the inlet water when determining
pg.
21 for an example on correcting the rated flow rate.
WARNING
DO NOT OPERATE THE SYSTEM BEYOND THE RATED PRODUCTION RATE!
DOING SO CAN CAUSE SCALING OR FOULING OF MEMBRANES.
NOTE
It is very important to meet the minimum feed water requirements. Failure to do so will
cause the membranes to foul and result in system underperformance.
Maximum Feed Temperature °F (°C) 95 (29) Maximum Free Chlorine ppm 0
Minimum Feed Temperature °F(°C) 40(4.4) Maximum TDS ppm 1,000
Maximum Ambient Temperature °F(°C) 110 (43.3) Maximum Hardness ppm 0
Minimum Ambient Temperature °F(°C) 40(4.4) Maximum pH (Continuous) 11
Maximum Feed Pressure psi (bar) 40(5.9) Minimum pH (Continuous) 5
Minimum Feed Pressure psi (bar) 15 (3.1) Maximum pH (Cleaning 30 min.) 12
Maximum Operating Pressure psi (bar) 150 (10.3) Minimum pH (Cleaning 30 min) 2
Minimum SDI Rating <1 Maximum Turbidity NTU 1
19

System Standard Operating Parameters
Standard Parameters
Total Dissolved Solids for Fresh Water Systems (PPM) Product Water Side
95% less than feed water
Temperature (F/C) 77/25
SYSTEMS
STANDARD
OPERATING
PARAMETERS
Fresh
Water
RO Systems
Product
Flow
(gpm/lpm)
Concentrate
Flow
(gpm/lpm)
Recycle Flow
(gpm/lpm)
(+/-10%)
Total Flow
(gpm/lpm)
Max Pump
Pressure
(psi/bar)
Max
Concentrate
Pressure
(psi/bar)
Pre
-
filter
Inlet Pressure
Minimum
(psi/bar)
Pre
-
filter
Inlet Pressure
Maximum
(psi/bar)
Pre
-
filter
Outlet
Pressure
Minimum
(psi/bar)
Pre
-
filter
Outlet Pressure
Maximum
(psi/bar)
SZ/ZTCII/XZ (FW-RO) SERIES
GPD 2000 1.4/5.3 1.0/3.8 2.0/7.6 4.4/16.7 150/10.3 150/10.3 15/1 85/4 15/1 85/4 GPD 3000 2.0/7.5 1.0/3.8 2.0/7.6 5/18.9 150/10.3 150/10.3 15/1 85/4 15/1 85/4
SZ-HD/XZ-HD (FW-RO) SERIES
GPD 4000 2.7/10.2 1.5/5.7 2.0/7.6 6.2/23.5 150/10.3 150/10.3 15/1 85/4 15/1 85/4 GPD 5000 3.47/13.1 1.5/5.7 2.0/7.6 7.0/26.5 150/10.3 150/10.3 15/1 85/4 15/1 85/4 GPD 6000 4.16/15.7 2.0/7.6 2.0/7.6 8.2/31 150/10.3 150/10.3 15/1 85/4 15/1 85/4
20